Electrosurgical pencil including improved controls

ABSTRACT

The present disclosure relates to electrosurgical devices having a plurality of hand-accessible variable controls. An electrosurgical device configured for connection to a source of electrosurgical energy is provided and includes a housing; an electrical circuit supported within the housing, the electrical circuit being connectable to the source of electrosurgical energy; and a controller slidably supported on the housing, wherein the controller is configured to exert a force on the electrical circuit to affect a change in the electrical circuit and to exert a force on a surface of the housing to provide a tactile feedback to a user of the electrosurgical device as the controller is moved relative to the housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Application Ser. No. 61/040,843 entitled “ELECTROSURGICAL PENCIL INCLUDING IMPROVED CONTROLS” filed Mar. 31, 2008 by Duane Kerr, which is incorporated by reference herein.

BACKGROUND

1. Technical Field

The present disclosure relates generally to electrosurgical instruments and, more particularly, to an electrosurgical pencil having a plurality of hand-accessible variable controls.

2. Background of Related Art

Electrosurgical instruments have become widely used by surgeons in recent years. Accordingly, a need has developed for equipment and instruments which are easy to handle, are reliable and are safe in an operating environment. By and large, most electrosurgical instruments are hand-held instruments, e.g., an electrosurgical pencil, which transfer radio-frequency (RF) electrical or electrosurgical energy to a tissue site. The electrosurgical energy is returned to the electrosurgical source via a return electrode pad positioned under a patient (i.e., a monopolar system configuration) or a smaller return electrode positionable in bodily contact with or immediately adjacent to the surgical site (i.e., a bipolar system configuration). The waveforms produced by the RF source yield a predetermined electrosurgical effect known generally as electrosurgical cutting and fulguration.

As used herein the term “electrosurgical pencil” is intended to include instruments which have a handpiece which is attached to an active electrode and which is used to cauterize, coagulate and/or cut tissue. Typically, the electrosurgical pencil may be operated by a handswitch or a foot switch. The active electrode is an electrically conducting element which is usually elongated and may be in the form of a thin flat blade with a pointed or rounded distal end. Alternatively, the active electrode may include an elongated narrow cylindrical needle which is solid or hollow with a flat, rounded, pointed or slanted distal end. Typically electrodes of this sort are known in the art as “blade”, “loop” or “snare”, “needle” or “ball” electrodes.

As mentioned above, the handpiece of the electrosurgical pencil is connected to a suitable electrosurgical energy source (i.e., generator) which produces the radio-frequency electrical energy necessary for the operation of the electrosurgical pencil. In general, when an operation is performed on a patient with an electrosurgical pencil, electrical energy from the electrosurgical generator is conducted through the active electrode to the tissue at the site of the operation and then through the patient to a return electrode. The return electrode is typically placed at a convenient place on the patient's body and is attached to the generator by a conductive material. Typically, the surgeon activates the controls on the electrosurgical pencil to select the modes/waveforms to achieve a desired surgical effect.

The power or energy parameters are typically controlled from outside the sterile field which requires an intermediary like a circulating nurse to make such adjustment.

A typical electrosurgical generator has numerous controls for selecting an electrosurgical output. For example, the surgeon can select various surgical “modes” to treat tissue: cut, blend (blend levels 1-3), low cut, desiccate, fulgurate, spray, etc. The surgeon also has the option of selecting a range of power settings typically ranging from 1-300 W. As can be appreciated, this gives the surgeon a great deal of variety when treating tissue. However, so many options also tend to complicate simple surgical procedures and may lead to confusion. Moreover, surgeons typically follow preset control parameters and stay within known modes and power settings. Therefore, there exists a need to allow the surgeon to selectively control and easily select and regulate the various modes and power settings utilizing simple and ergonomically friendly controls associated with the electrosurgical pencil.

Existing electrosurgical instrument systems allow the surgeon to change between two pre-configured settings (i.e., coagulation and cutting) via two discrete switches disposed on the electrosurgical pencil itself. Other electrosurgical instrument systems allow the surgeon to increment the power applied when the coagulating or cutting switch of the instrument is depressed by adjusting or closing a switch on the electrosurgical generator. The surgeon then needs to visually verify the change in the power being applied by looking at various displays and/or meters on the electrosurgical generator. In other words, all of the adjustments to the electrosurgical instrument and parameters being monitored during the use of the electrosurgical instrument are typically located on the electrosurgical generator. As such, the surgeon must continually monitor the electrosurgical generator during the surgical procedure. Furthermore, someone outside the sterile field must continually adjust the parameters of the electrical instrument, which prolongs the duration of the procedure.

Accordingly, the need exists for electrosurgical instruments which do not require the surgeon to continually monitor the electrosurgical generator during the surgical procedure. Further, a need exists for electrosurgical instruments, which permit the surgeon to accurately self-adjust the electrical parameters of the instrument from within the sterile field. In addition, the need exists for electrosurgical instruments which may be configured such that the power output can be adjusted without the surgeon having to turn his/her vision away from the operating site and toward the electrosurgical generator.

SUMMARY

The present disclosure relates to electrosurgical pencils having a plurality of hand-accessible variable controls.

According to an aspect of the present disclosure, an electrosurgical pencil is provided including an elongated housing configured to support an electrocautery electrode extending distally therefrom; at least one voltage divider network supported on the housing, the at least one voltage divider network operable to electrically connect to a source of electrosurgical energy for controlling at least one of an intensity and a mode of electrosurgical energy being delivered to the electrocautery electrode; and an intensity controller slidably supported on the housing. The intensity controller is configured to exert a force on the at least one voltage divider network and to provide a tactile feedback to a user of the electrosurgical pencil as the intensity controller is moved relative to the housing.

The intensity controller may include a nub extending from a surface thereof. The nub may be configured to contact the at least one voltage divider network and affect the at least one voltage divider network as the intensity controller is moved relative to the housing.

The intensity controller may include a spring plunger assembly configured to operatively engage a tactile feature formed in the housing. The spring plunger assembly may include a stem and a biasing member. The stem may be disposed on a side opposite to the nub and is configured to retain an actuator.

The biasing member may be configured to maintain the actuator in contact with the tactile feature formed in the housing. The actuator may be disposed at one of a distal, a proximal and a substantially aligned location with respect to the nub.

The intensity controller may include a spring lever assembly configured to operatively engage a tactile feature formed in the housing. The spring lever assembly may include a lever and a biasing member for maintaining the lever in contact with the tactile feature. The lever may be pivotally connected to a body portion of the intensity controller, on a side opposite to the nub.

The biasing member may be a spring.

A tip of the lever may be disposed at one of a distal, a proximal and a substantially aligned location with respect to the nub.

According to another aspect of the present disclosure, an electrosurgical device configured for connection to a source of electrosurgical energy is provided. The electrosurgical device includes a housing; an electrical circuit supported within the housing, the electrical circuit being connectable to the source of electrosurgical energy; and a controller slidably supported on the housing, wherein the controller is configured to exert a force on the electrical circuit to affect a change in the electrical circuit and to provide a tactile feedback to a user of the electrosurgical device as the controller is moved relative to the housing.

The controller may include a nub extending from a surface thereof and being dimensioned to contact the electrical circuit. The electrical circuit may be a voltage divider network capable of controlling at least one of an intensity and a mode of electrosurgical energy being delivered, and wherein the nub is configured to contact the voltage divider network and affect a change in at least one of the intensity and the mode of electrosurgical energy being delivered as the controller is moved relative to the housing.

The controller may include a spring plunger assembly configured to operatively engage a tactile feature formed in the housing. The spring plunger assembly may include a stem and a biasing member. The stem may be disposed on a side opposite to the nub and is configured to retain an actuator. The biasing member may be configured to maintain the actuator in contact with the tactile feature formed in the housing. The actuator may be disposed at one of a distal, a proximal and a substantially aligned location with respect to the nub.

The controller may include a spring lever assembly configured to operatively engage a tactile feature formed in the housing. The spring lever assembly may include a lever and a biasing member for maintaining the lever in contact with the tactile feature. The lever may be pivotally connected to a body portion of the intensity controller, on a side opposite to the nub. The biasing member may be a spring.

A tip of the lever may be disposed at one of a distal, a proximal and a substantially aligned location with respect to the nub.

According to a further aspect of the present disclosure, an electrosurgical pencil is provided including an elongated housing configured to support an electrocautery electrode extending distally therefrom; at least one voltage divider network supported on the housing, the at least one voltage divider network operable to electrically connect to the source of electrosurgical energy for controlling at least one of an intensity and a mode of electrosurgical energy being delivered to the electrocautery electrode; and an intensity controller slidably supported on the housing, wherein the intensity controller is configured to exert a force on the at least one voltage divider network and provide a tactile feedback to a user of the electrosurgical pencil as the intensity controller is moved relative to the housing.

The intensity controller may include a lever pivotally connected to a body portion thereof and contactable with the housing and the at least one voltage divider network. The lever may include a first end configured for engagement with a tactile feature formed in the housing. The lever may include a second end configured for engagement with the at least one voltage divider network.

The intensity controller may include a biasing member configured to maintain a first end of the lever in contact with the tactile feature formed in the housing. The intensity controller may include a biasing member configured to maintain a second end of the lever in contact with the at least one voltage divider network. The intensity controller may include a biasing member configured to maintain a first end of the lever in contact with the tactile feature formed in the housing and to maintain a second end of the lever in contact with the at least one voltage divider network.

The biasing members may be one of a coil spring, a tension spring and a compression spring. The tactile feature may include one or more adjacent detents. In use, movement of the first end of the lever into the one or more adjacent detents may cause the second end of the lever to substantially strike the at least one voltage divider network.

According to yet another aspect of the present disclosure, an electrosurgical device configured for connection to a source of electrosurgical energy is provided. The electrosurgical device includes a housing; an electrical circuit supported within the housing, the electrical circuit being connectable to the source of electrosurgical energy; and a controller slidably supported on the housing, wherein the controller is configured to exert a force on the electrical circuit to affect a change in the electrical circuit and to exert a force on a surface of the housing to provide a tactile feedback to a user of the electrosurgical device as the controller is moved relative to the housing.

The electrical circuit may comprise at least one voltage divider network capable of controlling at least one of an intensity and a mode of electrosurgical energy being delivered, and wherein the controller may include a lever pivotally connected to a body portion thereof and contactable with the housing and the at least one voltage divider network.

The lever may include a first end configured for engagement with a tactile feature formed in the housing. The lever may include a second end configured for engagement with the at least one voltage divider network.

The controller may include a biasing member configured to maintain a first end of the lever in contact with the tactile feature formed in the housing. The controller may include a biasing member configured to maintain a second end of the lever in contact with the at least one voltage divider network. The controller may include a biasing member configured to maintain a first end of the lever in contact with the tactile feature formed in the housing and to maintain a second end of the lever in contact with the at least one voltage divider network. The biasing members may be one of a coil spring, a tension spring and a compression spring.

The tactile feature may include one or more adjacent detents.

In use, movement of the first end of the lever into the one or more adjacent detents may cause the second end of the lever to substantially strike the at least one voltage divider network.

According to still another aspect of the present disclosure, an electrosurgical pencil is provided including an elongated housing configured to support an electrocautery electrode extending distally therefrom; at least one voltage divider network supported on the housing, the at least one voltage divider network operable to electrically connect to the source of electrosurgical energy for controlling at least one of an intensity and a mode of electrosurgical energy being delivered to the electrocautery electrode, wherein the at least one voltage divider network defines a plurality of tactile enhancement features; and an intensity controller slidably supported on the housing, wherein the intensity controller is configured to exert a force on the at least one voltage divider network and engage the tactile enhancement feature and provide a tactile feedback to a user of the electrosurgical pencil as the intensity controller is moved relative to the housing.

The electrosurgical pencil may further include a tactile mask overlying at least a portion of the at least one voltage divider network, wherein the tactile mask defines the plurality of tactile enhancement regions. The tactile enhancement features of the tactile mask may include at least one aperture formed therein.

The intensity controller may include a tactile feedback transmitting feature configured to project through the at least one aperture formed in the tactile mask to selectively engage the at least one voltage divider network. The tactile feedback transmitting feature may include at least one of an actuator and a nub selectively positionable within the aperture of the tactile mask.

At least one of an actuator and a nub may extend from a surface of the intensity controller, in a direction toward the tactile mask.

The tactile feedback transmitting feature may further comprise a spring plunger assembly including a biasing member for maintaining the tactile feedback transmitting feature in contact with at least one of the voltage divider network and the tactile mask.

The tactile feedback transmitting feature may be configured to selectively strike the at least one voltage divider network.

According to yet another aspect of the present disclosure, an electrosurgical device, configured for connection to a source of electrosurgical energy, is provided. The electrosurgical device comprises a housing; an electrical circuit supported within the housing, the electrical circuit being connectable to the source of electrosurgical energy, wherein the electrical circuit is provided with at least one tactile enhancement feature; and a controller slidably supported on the housing, wherein the controller is configured to exert a force on the electrical circuit to affect a change in the electrical circuit and to exert a force on a surface of the housing to engage the tactile enhancement feature and provide a tactile feedback to a user of the electrosurgical device as the controller is moved relative to the housing.

The electrosurgical device may further include a tactile mask overlying at least a portion of electrical circuit, wherein the tactile mask defines the plurality of tactile enhancement regions.

The tactile enhancement features of the tactile mask may include at least one aperture formed therein.

The controller may include a tactile feedback transmitting feature configured to project through the at least one aperture formed in the tactile mask to selectively engage the electrical circuit. The tactile feedback transmitting feature may include at least one of an actuator and a nub selectively positionable within the aperture of the tactile mask. At least one of an actuator and a nub may extend from a surface of the controller, in a direction toward the tactile mask.

The tactile feedback transmitting feature may further include a spring plunger assembly including a biasing member for maintaining the tactile feedback transmitting feature in contact with at least one of the electrical circuit and the tactile mask.

The tactile feedback transmitting feature may be configured to selectively strike the electrical circuit.

The electrical circuit may include at least one voltage divider network.

According to still another aspect of the present disclosure, an electrosurgical pencil is provided including an elongated housing configured to support an electrocautery electrode extending distally therefrom; at least one voltage divider network supported on the housing, the at least one voltage divider network operable to electrically connect to the source of electrosurgical energy for controlling at least one of an intensity and a mode of electrosurgical energy being delivered to the electrocautery electrode; and an intensity controller slidably supported on the housing, wherein the intensity controller is configured to exert a force on each of the housing and the at least one voltage divider network, wherein the intensity controller provides a tactile feedback to a user of the electrosurgical pencil as the intensity controller is moved relative to the housing.

The intensity controller may include a torsion spring pivotally supported on a body portion thereof wherein the torsion spring is in contact with at least one of the housing and the electrical circuit. The torsion spring may include a first leg configured for engagement with a tactile feature formed in the housing. The torsion spring may include a second leg configured for engagement with the at least one voltage divider network.

The torsion spring may include a first leg configured for engagement with a tactile feature formed in the housing and a second leg configured for engagement with the at least one voltage divider network.

The intensity controller may include a link assembly pivotally supported on a body portion. The link assembly may include a first leg configured for engagement with a tactile feature formed in the housing; and a second leg configured for engagement with the at least one voltage divider network.

The link assembly may further include a biasing member interposed between the first leg and the second leg for maintaining the first leg in engagement with the tactile feature formed in the housing and for maintaining the second leg in engagement with the at least one voltage divider network.

The biasing member may be configured for maintaining the first leg in engagement with the tactile feature formed in the housing. The biasing member may be configured for maintaining the second leg in engagement with the at least one voltage divider network.

According to still another aspect of the present disclosure, an electrosurgical device, configured for connection to a source of electrosurgical energy, is provided. The electrosurgical device comprises a housing; an electrical circuit supported within the housing, the electrical circuit being connectable to the source of electrosurgical energy; and a controller slidably supported on the housing, wherein the controller is configured to exert a force on each of the housing and the electrical circuit to affect a change in the electrical circuit and to provide a tactile feedback to a user of the electrosurgical device as the controller is moved relative to the housing.

The controller may include a torsion spring pivotally supported on a body portion thereof, wherein the torsion spring is in contact with at least one of the housing and the electrical circuit. The torsion spring may include a first leg configured for engagement with a tactile feature formed in the housing. The torsion spring may include a second leg configured for engagement with the electrical circuit. The torsion spring may include a first leg configured for engagement with a tactile feature formed in the housing and a second leg configured for engagement with the electrical circuit.

The controller may include a link assembly pivotally supported on a body portion. The link assembly may include a first leg configured for engagement with a tactile feature formed in the housing; and a second leg configured for engagement with the electrical circuit. The link assembly may further include a biasing member interposed between the first leg and the second leg for maintaining the first leg in engagement with the tactile feature formed in the housing and for maintaining the second leg in engagement with the electrical circuit. The biasing member may be configured for maintaining the first leg in engagement with the tactile feature formed in the housing. The biasing member may be configured for maintaining the second leg in engagement with the electrical circuit.

The electrical circuit may include at least one voltage divider network supported on the housing, the at least one voltage divider network operable to electrically connect to the source of electrosurgical energy for controlling at least one of an intensity and a mode of electrosurgical energy being delivered to the electrocautery electrode.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and together with a general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the invention.

FIG. 1 is a perspective view of a prior art electrosurgical system including an electrosurgical generator and an electrosurgical pencil;

FIG. 2 is an exploded perspective view of the electrosurgical pencil of FIG. 1;

FIG. 3 is a longitudinal, cross-sectional, side elevational view of the electrosurgical pencil of FIGS. 1 and 2;

FIG. 4 is an enlarged view of the indicated area of detail of FIG. 3;

FIG. 5 is an exploded perspective view of a voltage divider network;

FIG. 6A is a schematic side elevational view of a slider according to an embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 6B is a schematic side elevational view of a slider according to another embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 6C is a schematic side elevational view of a slider according to yet another embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 6D is a schematic perspective view, with parts separated, of a slider according to a further embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 7A is a schematic side elevational view of an alternate slider according to an embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 7B is a schematic side elevational view of the alternate slider according to another embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 7C is a schematic side elevational view of the alternate slider according to yet another embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 8A is a schematic illustration of a further alternate slider and a tactile mask according to an embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 8B is a schematic illustration of the further alternate slider according and a tactile mask to another embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 9A is a schematic side elevational view of an alternate slider according to an embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4; and

FIG. 9B is a schematic side elevational view of a further alternate slider according to another embodiment of the present disclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4.

DETAILED DESCRIPTION

Preferred embodiments of the presently disclosed electrosurgical pencil will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. As used herein, the term “distal” refers to that portion which is further from the user while the term “proximal” refers to that portion which is closer to the user or surgeon.

FIG. 1 sets forth a perspective view of an electrosurgical system including an electrosurgical pencil 100 constructed in accordance with a prior art embodiment. While the following description will be directed towards electrosurgical pencils it is envisioned that the features and concepts (or portions thereof) of the present disclosure can be applied to any electrosurgical type instrument, e.g., forceps, suction coagulators, vessel sealers, wands, etc.

As seen in FIGS. 1-5, electrosurgical pencil 100 includes an elongated housing 102 having a right-half shell section 102 a and a left-half shell section 102 b. As seen in FIGS. 1 and 2, when right and left-half shell sections 102 a, 102 b are connected to one another, a distal opening 103 a is defined therebetween, through which an electrode 106 extends, and a proximal opening 103 b (see FIG. 2) is defined therebetween, through which connecting cable 224 (see FIG. 1) extends. As seen in FIG. 1, electrosurgical pencil 100 is coupled to an electrosurgical generator “G” via a plug assembly 200 connected to connecting cable 224.

As seen in FIG. 2, electrosurgical pencil 100 further includes an electrode receptacle 104 disposed at a distal end of housing 102, and a replaceable electrode 106 operatively and removably connectable to electrode receptacle 104.

With continued reference to FIGS. 1-3, electrosurgical pencil 100 includes three activation buttons 120 a-120 c, each of which is reciprocally supported in a carrier 121 (see FIG. 2) of a controller unit which is supported in housing 102. Each activation button 120 a-120 c includes a portion which extends through an upper surface of housing 102.

As seen in FIGS. 2 and 3, each activation button 120 a-120 c is operatively supported on a respective tactile element 122 a-122 c formed in a switch plate 124.

Each activation button 120 a-120 c controls the transmission of RF electrical energy supplied from generator “G” to electrode 106. Switch plate 124 is positioned over the top of a voltage divider network 127 (hereinafter “VDN 127”) such that tactile elements 122 a-122 c are in operative association therewith.

As seen in FIGS. 1-4, electrosurgical pencil 100 includes an intensity controller 128 slidingly supported in housing 102. Intensity controller 128 includes a pair of nubs 129 a, 129 b which are slidingly supported, one each, in respective guide channels 130 a, 130 b (see FIG. 1).

As seen in FIGS. 3 and 4, intensity controller 128 includes a third nub 129 c extending from a bottom surface thereof which contacts and presses into or against VDN 127. As seen in FIG. 5, VDN 127 includes electrical contacts 144 a provided on upper layer 140 a and resistive element 144 b on lower layer 140 b. In this manner, as intensity controller 128 is displaced in a distal and proximal direction relative to housing 102, third nub 129 c moves along VDN 127, thereby pressing electrical contact 144 a from upper layer 140 a of VDN 127 against resistance element 144 b of lower layer 140 b of VDN 127. In so doing, a resistance value of resistance element 144 b is changed thereby changing the value of the voltage measured by electrosurgical generator “G”. The electrosurgical generator “G” in turn varies the intensity of the waveform being transmitted to electrode 106.

Slidable manipulation or movement of intensity controller 128 adjusts the power parameters (e.g., voltage, power and/or current intensity) and/or the power verses impedance curve shape to affect the output intensity of the waveform.

In order to vary the intensity of the power parameters of electrosurgical pencil 100, the surgeon displaces intensity controller 128, by manipulating at least one of nubs 129 a, 129 b, in either of the directions indicated by double-headed arrow “X” (see FIG. 3).

Intensity controller 128 is also operable to provide a degree of tactile feedback by the inter-engagement of resilient finger 128 a of intensity controller 128 in detents 131 formed along an inner surface of right-half shell section 102 a (see FIGS. 3 and 4).

As seen in FIG. 5, VDN 127 includes a pair of layers 140 a, 140 b of resilient material each supporting a plurality of electrical contacts 142 a, 142 b thereon. Electrical contacts 142 a from an upper layer 140 a of VDN 127 are in juxtaposed electrical relation with respect to electrical contacts 142 b from a lower layer 140 b of VDN 127. The electrical contacts 142 a, 142 b of the upper and the lower layers 140 a, 140 b of VDN 127 are in juxtaposed relation with respective tactile elements 122 a-122 c.

Upper and lower layers 140 a, 140 b of VDN 127 are separated by a dividing layer 140 c. Dividing layer 140 c includes a first series of apertures 142 c formed therein which are in vertical registration with electrical contacts 142 a, 142 b. Dividing layer 140 c includes a second aperture 144 c formed therein which is in vertical registration between electrical contacts 144 a provided on upper layer 140 a and a variable resistance element 144 d provided on lower layer 140 b. Upper layer 140 a, lower layer 140 b, and dividing layer 140 c are supported on a support layer 140 d.

In operation, and depending on the particular electrosurgical function desired, the surgeon depresses one of activation buttons 120 a-120 c, in the direction indicated by arrow “Y” (see FIG. 3) thereby urging and/or deflecting a corresponding tactile element 122 a-122 c against VDN 127 and thereby causing the respective electrical contact 142 a of upper layer 140 a to electrically engage the respective electrical contact 142 b of the lower layer 140 b. In so doing, a respective characteristic voltage is generated and measured by electrosurgical generator “C”. In turn, depending on the characteristic voltage generated, generator “G” selects and transmits an appropriate waveform output to electrocautery blade 106.

Reference may be made to U.S. application Ser. No. 11/337,990 filed on Jan. 24, 2006, the entire content of which is incorporated herein by reference, for a more detailed discussion of the construction and operation of electrosurgical pencil 100.

Turning now to FIGS. 6A-6D, a series of sliders or intensity controllers 228 according to an embodiment of the present disclosure is shown. Sliders 228 are configured to increase a contact force exerted on VDN 127 while maintaining a degree of facility for an end user to move slider 228 relative to housing 102 of electrosurgical pencil 100.

As seen in FIG. 6A, a slider 228 a may include a body portion 228 a ₁ and at least one arm 228 a ₂ extending from body portion 228 a ₁ and configured for slidable engagement in guide channels 130 a, 130 b (see FIG. 1) of electrosurgical pencil 100. Slider 228 a includes a nub 228 a ₃ extending or projecting from a bottom surface thereof, such as, for example, from a bottom surface of body portion 228 a ₁. Slider 228 a further includes a spring plunger assembly having a stem 228 a ₄ extending from body portion 228 a ₁, on a side opposite nub 228 a ₃, and defining a recess configured to retain a biasing member 228 a ₅ and an actuator 228 a ₆ therein. The spring plunger assembly is located distal or proximal of nub 228 a ₃.

In use, as slider 228 a is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, nub 228 a ₃ moves along VDN 127 thereby affecting VDN 127 while actuator 228 a ₆ of the spring plunger assembly inter-engages with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100 to thereby provide a degree of tactile feedback to the user of electrosurgical pencil 100. Biasing member 228 a ₅ functions to maintain nub 228 a ₃ in contact with VDN 127 and actuator 228 a ₆ of the spring plunger assembly in contact with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100.

As seen in FIG. 6B, a slider 228 b may include a body portion 228 b ₁ and at least one arm 228 b ₂ extending from body portion 228 b ₁ and configured for slidable engagement in guide channels 130 a, 130 b (see FIG. 1) of electrosurgical pencil 100. Slider 228 b includes a nub 228 b ₃ extending or projecting from a bottom surface thereof, such as, for example, from a bottom surface of body portion 228 b ₁. Slider 228 b further includes a spring lever assembly having a stem 228 b ₄ extending from body portion 228 b ₁, on a side opposite nub 228 b ₃, and defining a recess configured to retain a biasing member 228 b ₅ therein. The spring lever assembly further includes a lever 228 b ₆ pivotally connected to body portion 228 b ₁ and having a tip 228 b ₇ configured to extend over or overlie biasing member 228 b ₅. The spring lever assembly is configured such that stem 228 b ₄ is located distal or proximal of nub 228 b ₃ and such that lever 228 b ₆ extends away from nub 228 b ₃.

In use, as slider 228 b is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, nub 228 b ₃ moves along VDN 127 thereby affecting VDN 127 while tip 228 b ₇ of lever 228 b ₆ of the spring lever assembly inter-engages with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100 to thereby provide a degree of tactile feedback to the user of electrosurgical pencil 100. Biasing member 228 b ₅ functions to maintain nub 228 b ₃ in contact with VDN 127 and tip 228 b ₇ of lever 228 b ₆ of the spring lever assembly in contact with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100.

As seen in FIG. 6C, a slider 228 c may include a body portion 228 c ₁ and at least one arm 228 c ₂ extending from body portion 228 c ₁ and configured for slidable engagement in guide channels 130 a, 130 b (see FIG. 1) of electrosurgical pencil 100. Slider 228 c includes a nub 228 c ₃ extending or projecting from a bottom surface thereof, such as, for example, from a bottom surface of body portion 228 c ₁. Slider 228 c further includes a spring lever assembly having a biasing member 228 c ₅ supported on body portion 228 c ₁, on a side opposite nub 228 c ₃, and a lever 228 c ₆ pivotally connected to body portion 228 c ₁ and having a tip 228 c ₇ configured to extend over or overlie biasing member 228 c ₅. The spring lever assembly is configured such that biasing member 228 c ₅ is located distal or proximal of nub 228 c ₃ and such that lever 228 c ₆ extends away from nub 228 c ₃.

In use, as slider 228 c is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, nub 228 c ₃ moves along VDN 127 thereby affecting VDN 127 while tip 228 c ₇ of lever 228 c ₆ of the spring lever assembly inter-engages with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100 to thereby provide a degree of tactile feedback to the user of electrosurgical pencil 100. Biasing member 228 c ₅ functions to maintain nub 228 c ₃ in contact with VDN 127 and tip 228 c ₇ of lever 228 c ₆ of the spring lever assembly in contact with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100.

In each of sliders 228 a-228 c shown in FIGS. 6A-6C and described above, it is contemplated that in some embodiments that actuator 228 a ₆, or tips 228 b ₇, 228 c ₇ of levers 228 b ₆, 228 c ₆ may axially overlie respective nubs 228 a ₃-228 c ₃. In this manner, the force of the biasing member 228 a ₅-228 c ₅ acts directly in line with respective nubs 228 a ₃-228 c ₃.

Although the embodiment in FIGS. 6B-6C is shown to a use coil spring as the biasing member, it is contemplated that these slider designs may alternatively incorporate torsion springs of the type shown in FIG. 6D. As seen in FIG. 6D, a slider 228 d may include a body portion 228 d ₁ and at least one arm 228 d ₂ extending from body portion 228 d ₁ and configured for slidable engagement in guide channels 130 a, 130 b (see FIG. 1) of electrosurgical pencil 100. Slider 228 d includes a nub 228 d ₃ extending or projecting from a bottom surface thereof, such as, for example, from a bottom surface of body portion 228 d ₁. Slider 228 d further includes a torsion spring lever assembly supported on body portion 228 d ₁ having a biasing member 228 d ₅ and a connector rod 228 d ₈ pivotally connecting lever 228 d ₆ to body portion 228 d ₁ on a side adjacent nub 228 d ₃. Lever 228 d ₆ includes a tip 228 d ₇ configured such that biasing member 228 d ₅ is located distal or proximal of nub 228 d ₃.

In use, as slider 228 d is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, nub 228 d ₃ moves along VDN 127 thereby affecting VDN 127 while tip 228 d ₇ of lever 228 d ₆ of the spring lever assembly inter-engages with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100 to thereby provide a degree of tactile feedback to the user of electrosurgical pencil 100. Biasing member 228 d ₅ functions to maintain nub 228 d ₃ in contact with VDN 127 and tip 228 d ₇ of lever 228 d ₆ of the torsion spring lever assembly in contact with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100. One advantage to using a torsion spring lever assembly configuration as set forth in FIG. 6D is that such a configuration provides greater spring deflections with smaller spring constants, thus making the delivered force less sensitive to dimensional variations in slider 228 d.

Turning now to FIGS. 7A-7C, a series of sliders or intensity controllers 328 according to an embodiment of the present disclosure is shown. Sliders 328 are configured to increase a contact force exerted on VDN 127 while maintaining a degree of facility for an end user to move slider 328 relative to housing 102 of electrosurgical pencil 100.

As seen in FIGS. 7A-7C, a slider 328 a may include a body portion 328 a ₁ and at least one arm 328 a ₂ extending from body portion 328 a ₁ and configured for slidable engagement in guide channels 130 a, 130 b (see FIG. 1) of electrosurgical pencil 100. Slider 328 a includes a lever 328 a ₃ pivotally connected to body portion 328 a. Lever 328 a ₃ includes a first end 328 a ₄ configured to extend above body portion 328 a ₁ and a second end 328 a ₅ configured to extend below body portion 328 a ₁. First end 328 a ₄ of lever 328 a ₃ is configured to selectively engage detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100 and second end 328 a ₅ of lever 328 a ₃ is configured to selectively engage VDN 127.

As seen in FIG. 7A, slider 328 a may include a biasing member in the form of a coil or constant force spring 329 a, or as seen in FIG. 7B slider 328 a may include a biasing member in the form of a tensile spring 329 b, or as seen in FIG. 7C slider 328 a may include a biasing member in the form of a compression spring 329 c. Biasing members 329 a-329 c are each configured or arranged so as to maintain first end 328 a ₄ of lever 328 a ₃ in contact with or in engagement with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100 and to maintain second end 328 a ₅ of lever 328 a ₃ in engagement with VDN 127. Biasing members 329 a-329 c may be secured to and extend between a suitable location on lever 328 a ₃ and a suitable location on body portion 328 a ₁.

In use, as slider 328 a is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, first end 328 a ₄ of lever 328 a ₃ inter-engages with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100 to thereby provide a degree of tactile feedback to the user of electrosurgical pencil 100 while second end 328 a ₅ of lever 328 a ₃ moves along VDN 127 thereby affecting VDN 127. In particular, as first end 328 a ₄ of lever 328 a ₃ moves from one detent or tactile features 131 to an adjacent detent or tactile features 131, first end 328 a ₄ of lever 328 a ₃ is moved towards body portion 328 a ₁ and second end 328 a ₅ of lever 328 a ₃ moves off of or reduces a pressure on VDN 127 and also is moved towards body portion 328 a ₁. As first end 328 a ₄ of lever 328 a ₃ is moved into the adjacent detent or tactile features 131 second end 328 a ₅ of lever 328 a ₃ substantially strikes down onto, imparts or otherwise increases a pressure on VDN 127.

Turning now to FIGS. 8A and 8B, a series of sliders or intensity controllers 428 and a tactile mask 429 according to an embodiment of the present disclosure are shown. Sliders 428 are configured to increase a contact force exerted on VDN 127 while maintaining a degree of facility for an end user to move slider 428 relative to housing 102 of electrosurgical pencil 100. Tactile mask 429 is configured to cause slider 428 to impact or strike against VDN 127.

As seen in FIG. 8A, a slider 428 a may include a body portion 428 a ₁ and at least one arm 428 a ₂ extending from body portion 428 a ₁ and configured for slidable engagement in guide channels 130 a, 130 b (see FIG. 1) of electrosurgical pencil 100. Slider 428 a includes a spring plunger assembly having a stem 428 a ₄ extending from body portion 428 a ₁ and defining a recess configured to retain a biasing member 428 a ₅ and a tactile feedback transmitting feature in the form of an actuator 428 a ₆ therein. The spring plunger assembly is configured such that actuator 428 a ₆ extends from a bottom surface of body portion 428 a ₁, in the direction of VDN 127.

Tactile mask 429 includes an elongate body portion 429 a configured to overlie VDN 127. Body portion 429 a defines a plurality of apertures or windows 429 b formed therein along a length thereof. Tactile mask 429 is positioned over VDN 127 at a location such that apertures 429 b may align or register with variable resistance elements 144 d provided on lower layer 140 b of VDN 127 (see FIG. 5).

In use, as slider 428 a is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, actuator 428 a ₆ of spring plunger assembly moves over and between apertures 429 b formed in tactile mask 429. In so doing, actuator 428 a ₆ of spring plunger assembly impacts or strikes against VDN 127. Additionally, the inter-engagement of actuator 428 a ₆ of spring plunger assembly with apertures 429 b formed in tactile mask 429 provides a degree of tactile feedback to the user of electrosurgical pencil 100.

As seen in FIG. 8B, a slider 428 b may include a body portion 428 b ₁ and at least one arm 428 b ₂ extending from body portion 428 b ₁ and configured for slidable engagement in guide channels 130 a, 130 b (see FIG. 1) of electrosurgical pencil 100. Slider 428 b includes a tactile feedback transmitting feature in the form of a nub 428 b ₃ extending or projecting from a bottom surface thereof, such as, for example, from a bottom surface of body portion 428 b ₁. Slider 428 b further includes a spring lever assembly having a stem 428 b ₄ extending from body portion 428 b ₁, on a side opposite nub 428 b ₃, and defining a recess configured to retain a biasing member 428 b ₅ therein. The spring lever assembly further includes a lever 428 b ₆ pivotally connected to body portion 428 b ₁ and having a tip 428 b ₇ configured to extend over or overlie biasing member 428 b ₅. The spring lever assembly is configured such that stem 428 b ₄ is located distal or proximal of nub 428 b ₃ and such that lever 428 b ₆ extends away from nub 428 b ₃.

In use, as slider 428 b is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, nub 428 b ₃ of slider 428 b moves over and between apertures 429 b formed in tactile mask 429. In so doing, nub 428 b ₃ of slider 428 b contacts VDN 127. Additionally, the inter-engagement of nub 428 b ₃ of slider 428 b with apertures 429 b formed in tactile mask 429 provides a degree of tactile feedback to the user of electrosurgical pencil 100. Moreover, tip 428 b ₇ of lever 428 b ₆ rides against an inner surface of housing 102 of pencil 100 and biasing member 428 b ₅ act on tip 428 b ₇ of lever 428 b ₆ to exert a force on body portion 428 b ₁ and thereby press nub 428 b ₃ of slider 428 b against tactile mask 429.

Tactile mask 429 may be constructed from a rigid, semi-rigid or non-rigid material, from a resilient or non-resilient material, from a conductive or non-conductive material, from any combination thereof, or from any material suitable for the intended purpose of defining apertures and transmitting forces through said apertures.

Turning now to FIGS. 9A and 9B, a series of sliders or intensity controllers 528 according to an embodiment of the present disclosure is shown. Sliders 528 are configured to increase a contact force exerted on VDN 127 while maintaining a degree of facility for an end user to move slider 528 relative to housing 102 of electrosurgical pencil 100.

As seen in FIG. 9A, a slider 528 a may include a body portion 528 a ₁ and at least one arm 528 a ₂ extending from body portion 528 a ₁ and configured for slidable engagement in guide channels 130 a, 130 b (see FIG. 1) of electrosurgical pencil 100. Slider 528 a includes a biasing member, in the form of a torsion spring 528 a ₃ pivotally supported on body portion 528 a ₁ at pivot point “P”. Torsion spring 528 a ₃ includes a first leg 528 a ₄ extending from pivot point “P” and configured to engage a surface of housing 102 of electrosurgical pencil 100, and a second leg 528 a ₅ extending from pivot point “P” and configured to engage VDN 127. As seen in FIG. 9A, first leg 528 a ₄ of torsion spring 528 a ₃ extends above body portion 528 a ₁ and second leg 528 a ₅ of torsion spring 528 a ₃ extends below body portion 528 a ₁.

In use, as slider 528 a is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, second leg 528 a ₅ of torsion spring 528 a ₃ moves along VDN 127 thereby affecting VDN 127 while first leg 528 a ₄ of torsion spring 528 a ₃ inter-engages with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100 to thereby provide a degree of tactile feedback to the user of electrosurgical pencil 100. As first leg 528 a ₄ of torsion spring 528 a ₃ is flexed downwardly, in the direction of body portion 528 a ₁, as slider 528 a is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, second leg 528 a ₅ of torsion spring 528 a ₃ is pressed more or less into the surface of VDN 127.

As seen in FIG. 9B, a slider 528 b may include a body portion 528 b ₁ and at least one arm 528 b ₂ extending from body portion 528 b ₁ and configured for slidable engagement in guide channels 130 a, 130 b (see FIG. 1) of electrosurgical pencil 100. Slider 528 b includes a link assembly 528 b ₃ pivotally supported on body portion 528 b ₁ at pivot point “P”. Link assembly 528 b ₃ includes a first leg 528 b ₄ extending from pivot point “P” and configured to engage a surface of housing 102 of electrosurgical pencil 100, a second leg 528 b ₅ extending from pivot point “P” and configured to engage VDN 127, and a biasing member 528 b ₆ interposed between first leg 528 b ₄ a second leg 528 b ₅. As seen in FIG. 9B, first leg 528 b ₄ of link assembly 528 b ₃ is in registration with or extends above second leg 528 b ₅ of link assembly 528 b ₃.

In use, as slider 528 b is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, second leg 528 b ₅ of link assembly 528 b ₃ moves along VDN 127 thereby affecting VDN 127 while first leg 528 b ₄ of link assembly 528 b ₃ inter-engages with detents or tactile features 131 formed in housing 102 of electrosurgical pencil 100 to thereby provide a degree of tactile feedback to the user of electrosurgical pencil 100. As first leg 528 b ₄ of link assembly 528 b ₃ is moved downwardly, in the direction of body portion 528 b ₁, as slider 528 b is moved distally and proximally relative to housing 102 of electrosurgical pencil 100, biasing member 528 b ₆ transmits forces to second leg 528 b ₅ of link assembly 528 b ₃ to press more or less into the surface of VDN 127.

Although the subject apparatus has been described with respect to preferred embodiments, it will be readily apparent, to those having ordinary skill in the art to which it appertains, that changes and modifications may be made thereto without departing from the spirit or scope of the subject apparatus. 

What is claimed is:
 1. An electrosurgical apparatus, comprising: a housing including an electrode extending distally therefrom; a circuit supported in the housing and configured to control at least one of an intensity and a mode of electrosurgical energy being delivered to the electrode; and a controller slidably supported on the housing and having a biasing member operably disposed thereon, wherein the controller is configured to exert a force on the circuit and provide a tactile feedback to a user of the electrosurgical apparatus as the controller is moved relative to the housing; wherein the controller includes a spring lever assembly having (i) a stem extending from a body portion and (ii) a lever pivotally connected to the body portion and contactable with the housing and the circuit, the stem defining a recess configured to retain the biasing member therein and the lever having a tip configured to extend over and overlie the biasing member.
 2. The electrosurgical apparatus according to claim 1, wherein the tip of the lever is configured for engagement with a tactile feature formed in the housing.
 3. The electrosurgical apparatus according to claim 2, wherein a bottom portion of the lever is configured for engagement with the circuit.
 4. The electrosurgical apparatus according to claim 1, wherein the biasing member retained within the stem of the spring lever assembly is configured to maintain the tip of the lever in contact with a tactile feature formed in the housing.
 5. The electrosurgical apparatus according to claim 4, wherein the biasing member retained within the stem of the spring lever assembly is configured to maintain a bottom portion of the lever in contact with the circuit.
 6. The electrosurgical apparatus according to claim 1, wherein the biasing member is configured to maintain the tip of the lever in contact with a tactile feature formed in the housing and to maintain a bottom portion of the lever in contact with the circuit.
 7. The electrosurgical apparatus according to claim 1, wherein the biasing member is one of a coil spring, a tension spring, and a compression spring.
 8. The electrosurgical apparatus according to claim 6, wherein the tactile feature includes one or more adjacent detents.
 9. The electrosurgical apparatus according to claim 8, wherein movement of the tip of the lever into the one or more adjacent detents causes the bottom portion of the lever to substantially strike the circuit.
 10. The electrosurgical apparatus according to claim 1, wherein the body portion includes a nub projecting from a bottom portion thereof.
 11. The electrosurgical apparatus according to claim 10, wherein the stem is located distally or proximally of the nub, such that the lever extends away from the nub.
 12. The electrosurgical apparatus according to claim 10, wherein the nub is separate and distinct from the spring lever assembly. 